Apparatus for treating fabrics from an organic solvent

ABSTRACT

The present invention relates to an apparatus for treating fabrics from an organic solvent, e.g. dyeing, which apparatus comprises: A FORMULATION APPLICATION MODULE HAVING MEANS ASSOCIATED THEREWITH TO APPLY AN AGENT TO A FABRIC, A FIRST CHAMBER, IN FLUID COMMUNICATION WITH THE FORMULATION APPLICATION MODULE AND HAVING MEANS TO MAINTAIN A ZONE WITHIN THE CHAMBER FILLED WITH VAPORS OF AN ORGANIC SOLVENT, MEANS TO REMOVE SOLVENT VAPORS, AND MEANS, WHICH MAY BE THE SOLVENT VAPORS, TO EXCHANGE HEAT INTO THE FABRIC, A SECOND CHAMBER HAVING MEANS TO FLUSH AND WASH THE FABRIC, AND, A THIRD CHAMBER WHICH IS SUBSTANTIALLY IDENTICAL WITH THE FIRST SAID CHAMBER.

United States Patent [72) lnventor Sylvester Bergman Midland, Mich.

[211 Appl. No. 827,607

[22] Filed May 26, 1969 [45] Patented July 20, 1971 [73] Assignee TheDow Chemical Company Midland, Mich.

[541 APPARATUS FOR TREATING FABRICS FROM AN ORGANIC SOLVENT 3 Claims, 4Drawing Figs.

[52] US. Cl 68/5, 6.8/ [51] Int. Cl D061 43/06, D06c 1/06 [50] FieldotSearch 68/5, 9, 18, 20, 27

[56] References Cited UNITED STATES PATENTS 2,532,471 12/1950 Wedler68/9 X 2,724,254 11/1955 Zanger 68/9X 2,831,332 4/1958 Ross 68/9 PrimaryExaminerWilliam 1. Price Assistant Examiner-Philip R. Coe

An0rneysGriswold & Burdick, Glwynn R. Baker and C. E.

Rehberg ABSTRACT: The present invention relates to an apparatus fortreating fabrics from an organic solvent, e.g. dyeing, which apparatuscomprises: a formulation application module having means associatedtherewith to apply an agent to a fabric, a first chamber, in fluidcommunication with the formulation application module and having meansto maintain a zone within the chamber filled with vapors of an organicsolvent, means to remove solvent vapors, and means, which may be thesolvent vapors, to exchange heat into the fabric, a second chamberhaving means to flush and wash the fabric, and, a third chamber which issubstantially identical with the first said chamber.

PATENTED JUL2 0:971

SHEET 1 [1F 3 INVENTOR. 6 y/ 1/65 /s/' 56/9/77 on Y HT TORNL'Y PATENTEDJUL20 I97! INVENTOR. 5y/z/es/er Bergman 47'7ORNE Y APPARATUS FORTREATING FABRICS FROM AN ORGANIC SOLVENT BACKGROUND OF INVENTION Recentdevelopments in continuous treatment of fabrics with chemicals dissolvedor dispersed in an organic solvent have necessitated the development ofequipment to carry out these processes.

Neither the equipment which has been used for years to carry out batchprocesses nor the equipment which is used in treating fabrics on acontinuous basis is suitable for use with the new processes. Further,the present day equipment is large and expensive to build as well asoperate. While some of the equipment now in use might be adapted tocarry out, say the dyeing of carpets, the equipment presently employedto carry out process steps subsequent to the actual dyeing is notreadily adaptable to the continuous processing employing solvents.

It is therefore an object of the present invention to provide anapparatus which will enable the recently developed solvent dyeingprocesses and solvent-based fabric-treating processes to be employed ina continuous manner.

It is another object of the present invention to provide an apparatuscapable of conducting a textile treating process from a volatilesolvent, fixing the treating agent in the fabric and recovering thesolvent in an economical manner.

These and other objects will become apparent to those skilled in the artto which the invention pertains from the following specification andclaims.

BRIEF DESCRIPTION OF IN VENTION The apparatus of the present inventionis illustrated in the drawings:

FIG. 1 represents in schematic cross section one embodiment of anapparatus of the present invention comprised of a DETAILED DESCRIPTIONOF INVENTION One embodiment of the apparatus of the present inventionfor carrying out the chemical treatment of fabrics from organic solventsis illustrated in FIG. I. The illustration consists of a side elevation,in schematic diagram, ofa structure provided with an application moduleand three distinct chambers, each associated with the others for passageof a base material, e.g., floor covering, from the ambientenvironmentinto and out of each chamber and return to the ambient environment.

The description of the embodiment of the apparatus of FIG. I will havespecific reference to its use to d'yefloor covering; however, it is tobe understood that change in size and line speeds may be made to enablethe dyeing of lighter weight fabrics.

The drawing FIG. 1 has been divided into four sections, the firstsection I being the agent application module, the exact nature of whichis not a part of the present invention or apparatus since existingcommercial applicators can be employed. The second section 11 is theagent infusion and fixa tion chamber. The third section 12 is the rinsechamber and the fourth section 13 depicts the final drying section.

The agent infusion and fixation section 11 comprises a chamber 14 havingsix walls, two of the sidewalls l and I6, a bottom 17 and a top 18 areillustrated. The bottom 17 has, as illustrated a well 19 which isprovided with heating means 20. The heating means may be electrical,steam, or flame systems, commercially available and operative undertheconditions here employed, e.g., nature of solvent to be heated, etc.Along the sidewall is an opening 21 which is located near the upperextent of the sidewall 15. This opening 21 provides ingress into theinterior of the chamber 14 ofa base material 22, e.g., floor covering towhich a formulation has been applied. Located within the chamber I4extending peripherally around the interior walls at a point just belowthe opening-2l in sidewall 15 is a series of coils 23 which serve ascondensing surfaces for vapors which are generated within chamber 14.These coils 23 establishthe upper extent of the vapor zone 27 withinchamber 14.

Located directly below said coils 23 is a trough 24 to collect thecondensate from coils 23. The trough 24 is in fluid communication with astorage tank not shown and/or the well 19 supplying liquid vaporizablesolvent to the well 19 as well as solvent for preparation of dyeformulations- The interior of the chamber 14 is-provided with idlerrolls 25 located in a manner to direct the base material 22 into chamber14 in a-path 26 to maintain the base material 22 within the zone ofvapors 27 established between thc'condensing coils 23 and the bottom 17of the chamber 14. Positioned along the path 26 of the base material 22through zone 27 of chamber 14 are a series of superheatcrs 28. Thesesuperheaters 28 are illustrated as steam-heated finned radiators,although other means such as electrical heaters, gas-fired radiators andmicrowave generators as well as provisions for introducing superheatedvapors as shown in FIG. 2 arc suitable in their stead. I Y

The location of the condensing coils 23 is such that above the vaporlevel 27a established thereby is a. substantially vapor-free zone 29which is essentially quiescent'in nature. This zone 29 extends acrossand above each of the other units 12 and 13.

A series of idler rolls 30 are located within unit 12 to direct material22 along path 26 into chamber 31 which is the rinse unit 12. Locatedwithin rinse unit 12 chamber 31 are a series of nozzles 32 which areconnected to a pressurized source of rinse liquid. The lower portion ofchamber 3] is designedto hold a quantity of rinse liquid 33 sufficientto en'gult" the base material 22 during its passage through chamber 31.The nozzles are positioned in a manner such that their force is directedagainst the normal flow of liquid down the base material thus offsettingto some extent the effect of cascading'created by liquid flowingdownwardly over the fabric, particularly heavy nap of the-floor coveringwherein such flow causes the nap to bend with the flow. The chamber 31has been provided with a series of condensing coils 34 to condensevapors which might be generatedwithin chamber 33 and a trough 35 tocollect the condensed vapor thus preventing vapors from escaping intozone 29.

Unit 13 is similar in construction to unit II but is somewhat of amirror image thereof. Unit 11 .provides a means for removing rinsesolvent from the base material and recovering the so-removed solvent.Oftentimes it will not be economical or desirable to employ radiators 28such as shown in FIG. I. When such is not desired, it will be expedientto employ zones defined by plates traversing the path 26 of the-fabricas illustrated in FIG. 2 at 228. When such is employed, the well 19 andits associated heating coils 20 may be dispensed with. When employingthe plates 228, it .is of course necessary to provide a solventvaporizer 236 and a solvent vapor superheater 237.

Further, eventhe plates 228 illustrated in FIG. 2 are not alwaysessential. As shown in FIG. 3, a vaporizer 336 and superheater 337 aresupplied with liquid and vapors and open directly to the interior ofchamber 14.

Other modifications will become apparent to those skilled in the art.

The operation of the apparatus illustrated in the figures isself-evident and isreadily seen to permit conducting the novel methodtreating textile fabrics hereinbefore described. The treatment oftextiles in the apparatus of the present invention has been carried outemploying a prototype of the apparatus described in FIG. I with goodresults.

In the operation of the apparatus described hereinabove, the loss ofsolvent was about 5 percent of that introduced into the apparatus eitherin the agent formulation or as vapor and/or rinse liquor.

It is to be understood that when rinsing is not necessary to removeexcess agent, or unfixed agent or other assistants, etc., the rinsesection 12 and the drying unit 13 need not be employed. Thus one cantreat a fabric satisfactorily in an apparatus such as illustrated in H6.3.

Another embodiment of an apparatus for carrying out the presentinvention, as illustrated in FIG. 4, comprises a structure having threedistinct chambers, each associated with the others for passage of a basematerial, e.g., floor covering, from the ambient environment into andout of each chamber and return to the ambient environment. Thedescription of the embodiment of the apparatus of FIG. 4 will havespecific reference to its use to treat floor covering; however, it is tobe understood'that change in size and line speeds may be made to enablethe treatment of lighter weight fabrics.

FIG. 4 has been divided into four sections, the first section 410 beingthe agent applicator which is not a part of the present invention orapparatus since existing commercial dye applicators can be employed. Thesecond section 411 is the agent infusion and fixation chamber. The thirdsection 412 is the rinse chamber and the fourth section 413 depicts thefinal drying section.

The agent infusion and fixation section 411 comprises a chamber 414having sidewalls 415 and 416, a bottom 417 and a top 418. The sidewall415 is provided with vapor-heating means 428s. The heating means may beelectrical steam, or flame systems, commercially available and operativeunder the conditions here employed, e.g., nature of solvent to to beheated, etc. Along the sidewall 415 is an opening 421 which is locatednear the upper extent of the sidewall 415. This opening 421 providesingress into the interior of the chamber 414 ofa base material 422,e.g., floor covering to which a formulation has been applied. Locatedwithin the chamber 414 extending peripherally around the interior wallsat a point just below the opening 421 in sidewall 415 is a series ofcoils 423 which serve as condensing surfaces for vapors which aregenerated within chamber 414. These coils 423 establish the upper extentof the vapor zone 427 within chamber 414.

Located directly below said coils 423 is a trough 424 to collect thecondensate from coils 423. The trough 424 is in fluid communication witha storage tank not shown supplying liquid vaporizable solvent to thetreating agent formulations as well as that necessary to the heatingmeans 4280 to insure zone 427 is full of vapors.

The interior of the chamber 414 is provided with idler rolls 425 locatedin a manner to direct the base material 422 into chamber 414 in a path426 to maintain the base material 422 within the zone of vapors 427established between the condensing coils 423 and the bottom 417 of thechamber 414. Positioned along the path 426 of the base material 421through zone 427 of chamber 414 are a series of nozzles 428. Thesenozzles 428 are supplied with superheated vapors of a solvent throughheader 428a which is connected to the exterior piping 428b, asuperheater section 428e, a pipe 428d, a fan or blower 428e and a pipe428 f which is connected through the sidewall 415 of section 411.

The location of the condensing coils 423 is such that above the vaporlevel 427 a established thereby is a substantially vapor-free zone 429which is essentially quiescent in nature. This zone 429 extends acrossand above each of the other units 412 and 413.

A series of idler rolls 430 are located within unit 412 to directmaterial 422 into chamber 431 which is the rinse unit 412. Locatedwithin rinse unit 412 chamber 431 are a series of nozzles 432 which areconnected to a pressurized source of rinse liquid. The lower portion ofchamber 431 is designed to hold a quantity of rinse liquid 433sufficient to engulf the base material 421 during its passage throughchamber 431. The nozzles are positioned in a'manner such that theirforce is directed against the normal flow of liquid down the basematerial thus offsetting to some extent the effect of cascading createdby liquid flowing downwardly over the fabric. The

chamber 431 has been provided with a series of condensing coils 434 tocondense vapors which might be generated within chamber 433 and a trough435m collect the condensed vapor thus preventing vapors from escapinginto zone 429.

Unit 413 is similar in construction to unit 411 but is somewhat of amirror image thereof. Unit 411 provides a means for removing rinsesolvent from the base material and recovering the so-removed solvent. 7

Other modifications will become apparent to those skilled in the art. 7

In a representative operation of the apparatus described hereinabove todye carpets, the loss of solvent was about 5 percent of that introducedinto the apparatus either in the formulation or as vapor and/or rinseliquor.

lclaim:

1. An apparatus which comprises:

a formulation application module having means associated therewith toapply an agent dissolved in an organic solvent to a fabric;

a first chamber in fluid communication with the formulation applicationmodule and having means therein to maintain a zone within the chamberfilled with vapors of an organic solvent, means to condense the solventvapors and remove the condensate, and means to exchange heat into thefabric; I

a second chamber in fluid communication with said first chamber andhaving means to flush and wash the fabric; and,

a third chamber in fluid communication with said second chamber andhaving means therein to maintain a zone within the chamber filled withvapors of an organic solvent, means to condense the solvent vapors andremove the condensate, and means to exchange heat into the fabric.

2. An apparatus for removing volatile organic solvent from basematerials containing the same which comprises:

a first chamber having means of ingress and egress to said chamber,means to maintain a zone within the chamber filled with superheatedvapors of an organic solvent, means to condense the vapors of saidsolvent and to remove the condensate from said zone;

a second chamber in fluid communication with said first chamber throughan ingress and in fluid communication with a third chamber through anegress, having means to flush and wash the fabric consisting of seriesof spray nozzles located above a zone within said chamber which form abath; and,

a third chamber in fluid communication with the second said chamberhaving means of ingress and egress to said chamber, means to maintain azone within the chamber filled with superheated vapors of an organicsolvent, means to condense the vapors of said solvent and to remove thecondensate from said zone.

3. An apparatus comprising:

. a first chamber having:

a. means for ingress and egress to its interior from the ambientsurroundings,

b. means to condense a low boiling solvent vapor located below saidingress and egress and surrounding the interior walls of said chamber,

c. means associated with said chamber to provide vapors ofa low boilingsolvent,

(1. means within said chamber to direct in a continuous manner a textileweb through said chamber and maintain the web below the condensing meansduring a major portion of the travel of the web through said chamber;

2. a second chamber having:

a. an ingress and egress to and from its interior, said ingress being influid communication with the egress of said first chamber,

6 b. means within said second chamber to direct a textile below saidingress and egress and surrounding the inweb through said chamber,terior walls ofsaid chamber, c. means associated with said chamber torovid a on c. means associated with said chamber to provide vapors ofliquid through which the web will pass during its Ofalow botlmg Solvent,course th h h h b 5 d. means within said chamber to direct in acontinuous 3. a third hamber ha in manner a textile web through saidchamber and maina. an ingress and fluid to and from its interior, saidingress lain the web below the Condensing means durmg a major portion ofthe travel of the web through said being in fluid communication withsaid egress of said chamber.

second chamber, b. means to condense a low boiling solvent vapor located7 33 UNITEb STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No-3,5931,5 l3 Dated 20 July 1971 InVentOT(S) Sylvester Bergman It iscertified that error appears in the above-ideritifie'd patent and thatsaid Letters Patent are hereby corrected as shown below:

Column 3, line 69, insert along path N26 between "U22" and "into".

Column 5, Claim 3, line 7, delete "fluid" and insert egress Signed andsealed this 7th day of March 1972.

(SEAL) Attest:

EDWARD M.FLETCHER,JR. ROBERT GOTTSCHALK Attestlng Officer Commissionerof Patents

2. An apparatus for removing volatile organic solvent from basematerials containing the same which comprises: a first chamber havingmeans of ingress and egress to said chamber, means to maintain a zonewithin the chamber filled with superheated vapors of an organic solvent,means to condense the vapors of said solvent and to remove thecondensate from said zone; a second chamber in fluid communication withsaid first chamber through an ingress and in fluid communication with athird chamber through an egress, having means to flush and wash thefabric consisting of series of spray nozzles located above a zone withinsaid chamber which form a bath; and, a third chamber in fluidcommunication with the second said chamber having means of ingress andegress to said chamber, means to maintain a zone within the chamberfilled with superheated vapors of an organic solvent, means to condensethe vapors of said solvent and to remove the condensate from said zone.2. a second chamber having: a. an ingress and egress to and from itsinterior, said ingress being in fluid communication with the egress ofsaid first chamber, b. means within said second chamber to direct atextile web through said chamber, c. means associated with said chamberto provide a zone of liquid through which the web will pass during itscourse through the chamber;
 3. a third chamber having: a. an ingress andfluid to and from its interior, said ingress being in fluidcommunication with said egress of said second chamber, b. means tocondense a low boiling solvent vapor located below said ingress andegress and surrounding the interior walls of said chamber, c. meansassociated with said chamber to provide vapors of a low boiling solvent,d. means within said chamber to direct in a continuous manner a textileweb through said chamber and maintain the web below the condensing meansduring a major portion of the travel of the web through said chamber. 3.An apparatus comprising: